Braided Upper With Overlays For Article Of Footwear

ABSTRACT

An article of footwear includes a braided upper with overlay portions. The overlay portions may be applied to edges of the braided upper. The overlay portions can include eyelets to receive a lace. The overlay portions can extend around portions of the upper to reduce stretching and increase support. The overlay portions may facilitate attachment between the braided upper and a sole system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application61/839,097, filed Jun. 25, 2013, and titled “Article of Footwear withBraided Upper” (Attorney Docket No. 51-3210) the entirety of which isherein incorporated by reference and referred to throughout the detaileddescription as the “Braided Upper” application. This application is alsorelated to co-pending U.S. patent application Publication Number ______,now U.S. patent application Number ______, filed Jan. 24, 2014, and alsotitled “Article of Footwear with Braided Upper” (Attorney Docket No.51-3642) the entirety of which is herein incorporated by reference.

BACKGROUND

The present embodiments relate to articles of footwear and in particularto uppers for articles of footwear.

Athletic shoes often have two major components, an upper that providesthe enclosure for receiving the foot, and a sole secured to the upper.The upper may be adjustable using laces, hook-and-loop fasteners orother devices to secure the shoe properly to the foot. The sole has theprimary contact with the playing surface. The sole may be designed toabsorb the shock as the shoe contacts the ground or other surfaces. Theupper may be designed to provide the appropriate type of protection tothe foot and to maximize the wearer's comfort.

SUMMARY

In one aspect, an article of footwear includes an upper and a solesystem, where the upper made of a braided structure and an overlayportion. The overlay portion is bonded to the braided structure theoverlay portion is less resistant to stretching than the braidedstructure.

In another aspect, an article of footwear includes an upper and a solesystem, the upper being further associated with a lacing member. Theupper is made of a braided structure and an overlay portion and theoverlay portion includes a plurality of eyelets for receiving the lacingmember.

In another aspect, a method of making an article of footwear includesforming a braided structure with an interior cavity, cutting an openinginto the braided structure, thereby creating an opening in the braidedstructure and an edge associated with the opening and bonding an overlayportion to the edge, where the overlay portion includes a plurality ofeyelets. The method also includes inserting a lace through the eyeletsand associating a sole system with the braided structure to form thearticle of footwear.

Other systems, methods, features and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the embodiments, and be protected by the followingclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a schematic isometric view of an embodiment of an article offootwear including a braided upper with overlays;

FIG. 2 is an exploded isometric view of the article of footwear of FIG.1;

FIG. 3 is a schematic isometric view of the article of footwear of FIG.1, including an enlarged view of strands disposed against the overlay;

FIG. 4 is a schematic isometric view of another embodiment of anarrangement of strands bonded to an overlay;

FIG. 5 is a schematic isometric view of the article of footwear of FIG.1, including an enlarged cross-sectional view of an eyelet of theoverlay;

FIG. 6 is a schematic enlarged view of an embodiment of an overlayincluding eyelets, in which each eyelet is partially encircled by astrand of a braided upper;

FIG. 7 is a schematic enlarged view of another embodiment of an overlayincluding eyelets, in which strands of a braided upper do not encircleeach eyelet;

FIG. 8 is a schematic rear isometric view of an embodiment of an articleof footwear including a braided upper with overlays;

FIG. 9 is a schematic exploded isometric view of an embodiment of anarticle of footwear including a braided upper with multiple distinctoverlays;

FIG. 10 is a schematic side view of the article of footwear of FIG. 9;

FIG. 11 is a schematic top view of the article of footwear of FIG. 9;

FIG. 12 is a schematic isometric view of an embodiment of an article offootwear with two different braided regions and overlays covering thebraided regions;

FIG. 13 is a schematic isometric view of the article of footwear of FIG.12, in which a portion of the braided upper and an overlay are seen incross-section;

FIG. 14 is a side schematic view of an embodiment of a pre-cut braidedstructure shaped as an upper for an article of footwear;

FIG. 15 is a schematic view of a step of cutting the braided structureof FIG. 14 in order to form an opening in the upper, according to anexemplary process;

FIG. 16 is an isometric view of a step of joining an overlay to theupper of FIG. 15, according to an exemplary process;

FIG. 17 is an isometric view of an embodiment of a finished article offootwear constructed using the exemplary process of FIGS. 14-16;

FIG. 18 is an isometric view of an embodiment of a braided upper with anoverlay on a lower surface being associated with a sole member; and

FIG. 19 is an isometric view of the braided upper of FIG. 18 joined withthe sole member.

DETAILED DESCRIPTION

FIG. 1 is an isometric view of an embodiment of an article of footwear100, also referred to simply as article 100. Article 100 may beconfigured for use with various kinds of footwear including, but notlimited to: hiking boots, soccer shoes, football shoes, sneakers,running shoes, cross-training shoes, rugby shoes, basketball shoes,baseball shoes as well as other kinds of shoes. Moreover, in someembodiments article 100 may be configured for use with various kinds ofnon-sports related footwear, including, but not limited to: slippers,sandals, high heeled footwear, loafers as well as any other kinds offootwear, apparel and/or sporting equipment (e.g., gloves, helmets,etc.).

In some embodiments, article of footwear 100 may include upper 102 andsole system 110. Sole system 110 is secured to upper 102 and extendsbetween the foot and the ground when article 100 is worn. In differentembodiments, sole system 110 may include different components. Forexample, sole system 110 may include an outsole, a midsole, and/or aninsole. In some cases, one or more of these components may be optional.

Sole system 110 may provide one or more functions for article 100. Forexample, in some embodiments, sole system 110 may be configured toprovide traction for article 100. In addition to providing traction,sole system 110 may attenuate ground reaction forces when compressedbetween the foot and the ground during walking, running or otherambulatory activities. The configuration of sole system 110 may varysignificantly in different embodiments to include a variety ofconventional or non-conventional structures. In some cases, theconfiguration of sole system 110 can be selected according to one ormore types of ground surfaces on which sole system 110 may be used.Examples of ground surfaces include, but are not limited to: naturalturf, synthetic turf, dirt, as well as other surfaces.

Generally, upper 102 may be any type of upper. In particular, upper 102may have any design, shape, size and/or color. For example, inembodiments where article 100 is a basketball shoe, upper 102 could be ahigh top upper that is shaped to provide high support on an ankle. Inembodiments where article 100 is a running shoe, upper 102 could be alow top upper.

Referring to FIG. 1, for purposes of reference, components of article100, such as upper 102, may be divided into forefoot portion 10, midfootportion 12 and heel portion 14. Forefoot portion 10 may be generallyassociated with the toes and joints connecting the metatarsals with thephalanges. Midfoot portion 12 may be generally associated with the archof a foot. Likewise, heel portion 14 may be generally associated withthe heel of a foot, including the calcaneus bone. In addition, upper 102may include lateral side 16 and medial side 18. In particular, lateralside 16 and medial side 18 may be opposing sides of article 100.Furthermore, both lateral side 16 and medial side 18 may extend throughforefoot portion 10, midfoot portion 12 and heel portion 14.

It will be understood that forefoot portion 10, midfoot portion 12 andheel portion 14 are only intended for purposes of description and arenot intended to demarcate precise regions of upper 102. Likewise,lateral side 16 and medial side 18 are intended to represent generallytwo sides of upper 102, rather than precisely demarcating upper 102 intotwo halves.

For consistency and convenience, directional adjectives are employedthroughout this detailed description corresponding to the illustratedembodiments. The term “longitudinal” as used throughout this detaileddescription and in the claims refers to a direction extending a lengthof a component. For example, the longitudinal direction of upper 102 mayextend from forefoot portion 10 to heel portion 14 of upper 102. Also,the term “lateral” as used throughout this detailed description and inthe claims refers to a direction extending along a width of a component.For example, the lateral direction of upper 102 may extend betweenmedial side 18 and lateral side 16 of upper 102. Additionally, the term“vertical” as used throughout this detailed description and in theclaims refers to a direction that is perpendicular to both thelongitudinal and lateral directions.

In addition, the term “proximal” refers to a portion of a footwearcomponent that is closer to a portion of a foot when an article offootwear is worn. Likewise, the term proximal direction refers to adirection oriented towards a foot when an article is word. The term“distal” refers to a portion of a footwear component that is furtherfrom a portion of a foot when an article of footwear is worn. The distaldirection refers to a direction oriented away from a foot when anarticle is worn.

In some embodiments, upper 102 may be comprised of a braided structure,such as a braided fabric or other braided structure. Braided structurescan be formed by intertwining three or more strands of yarn, filamentsor other fibers to form the structure. As an example, upper 102 as seenin FIG. 1 is formed from a plurality of strands 130 that are braidedtogether to form a shape that is globally similar to the shape of afoot.

Braiding can be used to form three-dimensional structures, by braidingstrands of yarn over a form or a last. Strands of the braided structure,such as plurality of strands 130 of the exemplary embodiment, can befabricated from fibers such as nylon, carbon, polyurethane, polyester,cotton, aramid (e.g., Kevlar®), polyethylene or polypropylene. Thesestrands can be braided to form three-dimensional structures for a widevariety of applications.

Braided structures may be fabricated manually, or may be manufacturedusing automated braiding machinery, such as the machinery disclosed inU.S. Pat. Nos. 7,252,028; 8,261,648; 5,361,674; 5,398,586; and4,275,638, all of which are incorporated by reference in their entiretyherein. Such three-dimensional braided structures may also bemanufactured to a specific design by, for example, TEF Braids,Warrensburg, N.Y. or A&P Technology, Cincinnati, Ohio.

By using braiding, uppers for articles of footwear may be engineeredwith specific features tailored to a particular athletic or recreationalactivity. Braided uppers can be very light while conforming closely andcomfortably to the wearer's feet. In some embodiments, the fit of theupper may be adjusted to provide the specific degree of tension ortightness the wearer may prefer. Braided uppers are characterized byclose containment over the wearer's foot. In some embodiments, thebraided fabric may wrap all the way around the footwear, as shown in thefigures. Such a structure has tensional integrity or “tensegrity,” sincethe wearer's foot is in compression, while the braided strands are intension around the wearer's foot.

Some embodiments may include braided uppers that extend beneath thefoot, thereby providing 360 degree coverage at some regions of the foot.However, other embodiments need not include uppers that extend beneaththe foot. In other embodiments, for example, a braided upper could havea lower periphery joined with a sole structure and/or sock liner.

FIG. 2 illustrates an exploded isometric view of an embodiment ofarticle 100, including upper 102 which is comprised of a braidedstructure. Referring to FIGS. 1-2, upper 102 is seen to have an opening120 that may receive a foot. Additionally, upper 102 has a fasteningregion 124. Fastening region 124 may further include a fastening gap 125that separates a lateral fastening edge 126 from a medial fastening edge127 (see FIG. 2).

Fastening region 124 may be further associated with that a fasteningmember 160. In the exemplary embodiment, fastening member 160 may be alace. In other embodiments, however, fastening member 160 could be anyother kind of fastener including but not limited to, straps, snaps,buttons, zippers, hook and loop fasteners (e.g., Velcro), as well asother kinds of fasteners.

Embodiments utilizing braided uppers can include provisions to helpprovide additional structure to the upper. In some embodiments, forexample, an article may include one or more additional material portionsthat are bonded or otherwise attached to specific portions of thebraided upper in order to enhance various characteristics of the upper.For example, these material portions may be used to increase strengthand durability, provide stretch resistance at certain locations of theupper and facilitate the joining of other components with the braidedstructure.

Throughout the detailed description and in the claims, the term “overlayportion”, or simply overlay, refers to any portion of material that isattached to a surface of a braided structure, such as a braided upper.In some embodiments, an overlay portion is comprised of a distinctmaterial from the strands of the braided structure. Moreover, in someembodiments, an overlay portion may have substantially differentmaterial characteristics from the strands of the braided structure. Inan exemplary embodiment, an overlay portion may resist stretching incomparison to a corresponding portion of a braided structure.

Generally, an overlay portion may be formed of any material. Exemplarymaterials include, but are not limited to: fabrics (including woven andnon-woven fabrics), leathers (including natural and synthetic leathers),polymer materials, as well as other kinds of materials. In oneembodiment, one or more overlay portions may be made of thermoplasticpolyurethane (TPU).

In an exemplary embodiment, article 100 may be associated with overlaycomponent 140. Overlay component 140 may be further comprised of severaldifferent overlay portions, including a first overlay portion 150, asecond overlay portion 152 and a third overlay portion 154. Each overlayportion may be provided at a specific location on upper. For example,first overlay portion 150 may be associated with fastening region 124 ofupper 102. Likewise, second overlay portion 152 may be associated withopening 120. Finally, third overlay portion 154 may be associated withheel portion 14 as well as portions of both lateral side 16 and medialside 18 of upper 102.

Referring now to FIG. 2, in some embodiments, first overlay portion 150extends along the edges of fastening region 124. In particular, firstoverlay portion 150 includes a first section 181 that is associated withlateral fastening edge 126 of fastening region 124. Also, first overlayportion 150 includes a second section 182 that is associated with medialfastening edge 127 of fastening region 124. In some embodiments, anintermediate section 183 runs along a forward most edge 129 of fasteningregion 124 and joins first section 181 and second section 182 of firstoverlay portion 150.

With this configuration, first overlay portion 150 may form, or formpart of, the lateral and medial eyestays for upper 102. In particular,first overlay portion 150 may facilitate the attachment of upper 102with fastening member 160. As discussed in further detail below, the useof overlay portions along the edges of fastening region 124 may help tomore evenly distribute the tensioning forces applied by fastening member160 to upper 102.

In at least some embodiments, first overlay portion 150 may help finishthe braided structure of upper 102 along lateral fastening edge 126,medial fastening edge 127 and forward most edge 129 of fastening region124. Specifically, in embodiments where the strands of the braidedstructure may be open at any of lateral fastening edge 126, medialfastening edge 127 or forward most edge 129, first overlay portion 150may help to bond, fuse or otherwise hold the ends of the strands inplace in order to prevent unraveling of the strands along these edges.

In some embodiments, second overlay portion 152 extends along the edgesof opening 120. In particular, second overlay portion 152 is associatedwith opening edge 195. In some embodiments, moreover, second overlayportion 152 is substantially continuous with first overlay portion 150,such that all of the edges of upper 102 associated with opening 120and/or the opening at fastening region 124 are covered by first overlayportion 150 or second overlay portion 152.

This arrangement helps to finish opening edge 195 by bonding any openstrands to second overlay portion 152. In addition, second overlayportion 152 may help reinforce opening 120, so that the braidedstructure in the vicinity of opening 120 may not be overly stretched.Such reinforcement may be especially useful at opening 120, sinceopening 120 may undergo a great deal of pulling and other stress as auser inserts and/or removes his or her foot.

In some embodiments, third overlay portion 154 may include a firstsection 171 that extends along lateral side 16 and a second section 172that extends along medial side 18 of upper 102. Additionally, a thirdsection 173 of third overlay portion 154 may extend beneath (e.g., on alower side of) upper 102 at heel portion 14. In some embodiments, thirdsection 173 joins first section 171 and second section 172 so that thirdoverlay portion 154 wraps continuously around the sides and bottom ofupper 102.

In some embodiments, first section 171 of third overlay portion 154extends from, and is continuously formed with, first section 181 offirst overlay portion 150. Additionally, in some embodiments, secondsection 172 of third overlay portion 154 extends from, and iscontinuously formed with, second section 182 of first overlay portion150. Because third overlay portion 154 may act to reduce stretchingalong its length, this configuration may help increase support under theheel by resisting stretching of the upper between first overlay portion150 (at the top of the foot) and the lower side 199 (see FIG. 8) of heelportion 14.

FIG. 3 illustrates an enlarged view of a portion of article 100 wheresome strands may be bonded to a second overlay portion 152. Referring toFIG. 3, some strands 304 may be disposed against inner surface 302second overlay portion 152. In this exemplary embodiment, strands 304may form part of a closed woven edge 305 of upper 102 that lacks anyloose or free ends of strands. In this case, strands 304 may be bondedto second overlay portion 152 to reinforce the continuously wovensection of the braided structure.

In an alternative embodiment, shown in FIG. 4, some strands 470 may beconfigured with loose or free ends 472. In this configuration, open ends472 may be secured to overlay portion 452 in order to keep strands 470in place and help prevent strands 470 from loosening or unraveling. Thusit can be seen that in some embodiments, an overlay portion may be usedto retain the loose or free ends associated with the edge of a braidedstructure. Such an arrangement may provide a means of finishing cutedges of the braided structure, or any edges that include loose or freeends that might unravel.

The arrangement described here provides an overlay portion that may actto reinforce the edge of the braided structure at opening 120. This mayhelp reduce stretching of upper 102 at opening 120, in order to preservethe structural integrity of upper 102. In addition, second overlayportion 152 may help secure any loose or open ends of the braidedstructure to prevent fraying of the ends and/or unraveling of thebraided structure.

Various processes for bonding an overlay portion to a braided structure,such as a braided upper, are discussed in further detail below.Exemplary materials used for bonding can include any known adhesives,melts, resins or other bonding agents.

FIG. 5 illustrates an isometric view of article 100, including anenlarged schematic cross-sectional view of a portion of first overlayportion 150 and fastening member 160. Referring to FIG. 5, first overlayportion 150 includes a plurality of eyelets 400. Specifically, pluralityof eyelets 400, including eyelet 402 shown in the enlargedcross-section, are openings in first overlay portion 150 that areconfigured to receive portions of fastening member 160.

In contrast to an alternative embodiment where strands of upper 102 maydirectly secure portions of a fastening member, the exemplary embodimentis configured so that strands of upper 102 are indirectly secured tofastening member 160 via eyelets in first overlay portion 400.Specifically, strands 410 are seen to be secured directly to firstoverlay portion 150, while fastening member 160 is secured throughplurality of eyelets 400 in first overlay portion 150. Thisconfiguration may distribute forces imparted by fastening member 160more evenly across the braided structure of upper 102. This may preventfastening member 160 from tugging too much on a particular strand, forexample, thereby facilitating better comfort and fit of article 100 on afoot.

FIGS. 6 and 7 illustrate two possible configurations for strands in thevicinity of eyelets on an overlay portion. Referring first to FIG. 6, insome embodiments, one or more strands may extend around an eyelet,thereby acting to reinforce the eyelet. For example, in FIG. 6, firststrand 512 and second strand 514 wrap around first eyelet 502 and secondeyelet 504, respectively. This may have the effect of reinforcing firsteyelet 502 and second eyelet 504, as well as providing a more directtransfer of tension between fastening member 160 and the braided strandsof upper 102.

Referring to an alternative embodiment shown in FIG. 7, first eyelet 502and second eyelet 504 are not surrounded by any strands of the upper. Inparticular, it may be seen that strands 610 are bonded to first overlayportion 150 without encircling first eyelet 502 and second eyelet 504.Of course, in still other embodiments, some eyelets may be surrounded orreinforced by strands while other eyelets may not be surrounded orreinforced.

FIG. 8 illustrates a rear isometric view of upper 102, in which strands130 of upper 102 are shown in phantom. Referring to FIG. 7, thirdoverlay component 156 is seen to wrap underneath a bottom side 199 ofupper 102 at heel portion 14. In some cases, this configuration allowsthird overlay portion 156 to cradle the heel of the foot. Thus, thisarrangement may provide further support for the heel of the foot whenarticle 100 is worn by reducing stretching through heel portion 14.

In some embodiments, multiple distinct overlay components may be used.In some embodiments, distinct overlay components may be configured tointersect or overlap at predetermined portions of an upper. Suchconfigurations of overlapping overlay components may provide a means forenhancing strength and stretch resistance over large portions of anupper, including, possibly, the entirety of the upper.

FIGS. 9-11 illustrate an embodiment of an article of footwear 800,comprising an upper 802 and a sole structure 805 (shown in FIG. 10only). Referring first to FIG. 9, upper 802 is comprised of a braidedstructure that is braided from a plurality of strands 830. In addition,multiple overlay components are associated with upper 802, including afirst overlay component 810, a second overlay component 812, a thirdoverlay component 814 and a fourth overlay component 816.

In the exemplary embodiment, each overlay component is associated with aparticular portion of upper 802. For example, first overlay component810 is associated with the edges 870 of opening 860 and fastening region862. Thus, in some cases, first overlay component 810 may be used tofinish plurality of strands 830 along edges 870. Additionally, firstoverlay component 810 may provide stretch resistance in the vicinity ofopening 860.

Second overlay component 812 is associated with forward toe portion 868of upper 802. In some embodiments, second overlay component 812 may helpimprove stretch resistance at forward toe portion 868. Additionally, insome embodiments, second overlay component 812 may provide a coveringfor forward toe portion 868. In particular, the presence of secondoverlay component 812 may help prevent debris from entering upper 802through forward toe portion 868.

Third overlay component 814 may be associated with a forefoot portion811 of upper 802. In some embodiments, third overlay component 814 maybe positioned forwards of fastening region 862. Furthermore, as clearlyseen in FIG. 9, third overlay component 814 may completely encircleupper 802 (and a foot within upper 802). In an exemplary embodiment,third overlay component 814 is comprised of a first band 817 and asecond band 819, which are integrally joined at top intersection region815. This arrangement may therefore provide targeted stretch resistanceat forefoot portion 811 that enhances support of the foot duringactivities where forefoot portion 811 may be firmly planted on theground.

Fourth overlay component 816 may be associated with heel portion 813 ofupper 802. In some embodiments, fourth overlay component 816 may providea heel-counter like overlay portion 825, as well as a strap-like overlayportion 827. In combination, overlay portion 825 and overlay portion 827may help limit stretching at heel portion 813 and may therefore enhancesupport of the heel within upper 802.

As seen in FIGS. 10-11, when assembled with upper 802, some of theoverlay components may overlap with one another. For example, thirdoverlay component 814 is clearly seen to overlap with portions of firstoverlay component 810 at an overlap region 902. In addition, thirdoverlay component 814 is seen to overlap with portions of second overlaycomponent 812 at an overlap region 903. Likewise, fourth overlaycomponent 816 is clearly seen to overlap with portions of first overlaycomponent 810 at an overlap region 904. This overlapping arrangement mayhelp enhance the structural integrity of upper 802, since portions ofone overlay component may reinforce the support of an overlappingoverlay component. Moreover, by overlapping and joining portions ofdifferent overlay components together, the overlay components mayfunction as a unitary frame for supporting the braided structure ofupper 802.

Embodiments utilizing braided regions having different properties mayinclude provisions for further reinforcing some regions but not others.In some embodiments, an article may include an overlay portion that isconfigured to cover a predetermined region of the article.

FIGS. 12 and 13 illustrate isometric views of an article 1100 that isconfigured with overlay portions that cover two specific regions of anupper 1102. Specifically, FIG. 12 illustrates an isometric exploded viewof article 1100, while FIG. 13 illustrates an isometric view includingan enlarged cross-sectional view. Referring to FIGS. 12 and 13, article1100 includes upper 1102 and sole system 1110. Upper 1102 is furtherconfigured with at least four distinct regions, including a first region1151, a second region 1152, a third region 1153 and a fourth region1154. In the exemplary embodiment, first region 1151 is a toe region ofupper 1102. Second region 1152 is disposed directly adjacent to, andrearwards of, first region 1151. Third region 1153 is disposed adjacentto, and rearwards of, second region 1152. Finally, fourth region 1154extends rearwards of third region 1153. Moreover, fourth region 1154 isa substantially larger region than the remaining regions, and includesthe entirety of midfoot portion 1103 and heel portion 1105 of upper1102. Thus, first region 1151, second region 1152 and third region 1153may be characterized as bands of upper 1102 that extend laterally acrossupper 1102.

Each region of upper 1102 may be associated with a particular materialcharacteristic, such as a braiding density. In the exemplary embodiment,first region 1151 and third region 1153 are both associated with a firstbraiding density, while second region 1152 and fourth region 1154 areassociated with a second braiding density. In some embodiments, thefirst braiding density may be greater than the second braiding density.Thus, first region 1151 and third region 1153 are more tightly braidedand may provide regions of increased strength and may also resiststretching in some embodiments.

Article 1100 may be further associated with first overlay portion 1160and second overlay portion 1162. First overlay portion 1160 may beshaped to cover first region 1151 of upper 1102. Second overlay portion1162 may be shaped to cover third region 1153 of upper 1102. Forexample, as shown in the enlarged cross-sectional view of FIG. 13,second overlay portion 1162 may be disposed over strands 1170 of thirdregion 1153. With this arrangement, first overlay portion 1160 andsecond overlay portion 1162 may further reinforce first region 1151 andsecond region 1153, thereby enhancing support and stretch resistance inthese regions.

The exemplary embodiments are only intended to illustrate some possibleconfigurations for overlay portions on an upper. It should be understoodthat some other embodiments may include overlay portions configured in avariety of different shapes, sizes and locations. Moreover, any numberof distinct overlay components can be used in alternative embodiments.The number, shape, size and location of overlay components or overlayportions can be selected to achieve desired properties including stretchresistance, enhanced strength, support, comfort or any other desiredproperties at any locations on an article of footwear.

As discussed in the Braided Upper application, braided uppers can beconfigured with a variety of different features and functionality. Itshould be understood that the overlay portions described in thisdetailed description may be utilized with a variety of differentembodiments of braided uppers, which may or may not include some of thefeatures discussed in the Braided Upper application. As an example, insome embodiments, strands with different material properties could bebraided together, or otherwise associated with one another, to providespecific properties at one or more regions of an upper. For example, anupper may be fabricated from fibers that stretch to a certain degree, asthe wearer's foot moves through each stride he or she takes, thusincreasing the wearer's comfort. In that case, high tensile strength,non-stretch fibers may be threaded through those specific regions of thefootwear that require additional structural support. As another example,an upper may be fabricated with a more open braid in some areas, forexample to improve breathability or comfort. In that case, additionalfibers may be laced through the braid to provide additional support incertain parts of those areas, or to provide increased durability forhigh-impact regions of the footwear. An upper having any of theseconfigurations may be further associated with one or more overlayportions in order to further control the characteristics andfunctionality of the upper, including support and/or stretch resistancein various areas of the upper.

The upper may also have floating cables, i.e., cables that are notbraided into the fabric of the upper may be used to relieve the stresson certain sections of the upper. The floating cables may be made of adifferent material that is separate from and not attached to the braidedstructure. The cables may also be used as laces to secure the footwearto the foot, or to tighten up certain parts of the footwear, asdescribed below. For example, the cables may be anchored at a first endat the sole of the footwear, and at a second end at an eyelet, forexample. Such floating cables may also be used to add to the support andstability of certain parts of the footwear, such as around the ankleopening. In some embodiments, overlay portions may be used with braideduppers incorporating floating cables, and in some cases the overlayportions may be used to reinforce portions with cables or portionswithout cables. In some embodiments, overlay portions could be used tohelp anchor ends of the floating cables to the upper.

The combination of these features, including any of the featuresdescribed in the Braided Upper application, in conjunction with theoverlay portions described above and shown in the figures may facilitatethe creation of uppers tailored to a particular athletic or recreationalactivity. Braided uppers with combinations of these features can be verylight while conforming closely and comfortably to the wearer's feet. Insome embodiments, the fit of the upper may be adjusted to provide thespecific degree of tension or tightness the wearer may prefer.

FIGS. 14-17 illustrate several steps in an exemplary process of formingan article comprised of a braided upper and overlay portions. Initially,as shown in FIG. 14, a braided upper 1402 may be formed using any kindof braiding process. An exemplary process for forming braided articlesis disclosed in the Braided Upper application, which has been previouslydiscussed and incorporated by reference. Next, as shown in FIG. 15, insome embodiments, an opening 1502 may be cut into upper 1402. This maycreate a new edge 1504 that bounds opening 1502. Opening 1502 may beused for insertion of a foot, and may provide a region for a fastener,such as a lace.

In an exemplary embodiment, an overlay portion 1510 may then be bondedalong edge 1504 (see FIG. 15) of upper 1402, as shown in FIG. 17. Insome embodiments, the bonding may be achieved using a welding process,such as an ultrasonic welding process. The strands exposed along edge1504 may thereby be fused to overlay portion 1510 to finish the ends aswell as to reinforce and support edge 1504 when the article is fastened.Finally, as shown in FIG. 17, a lace 1602 may be inserted througheyelets 1610. Additionally, in some embodiments, a sole system 1620 maybe added to the bottom of upper 1402.

Some embodiments can include provisions to facilitate the joining of anupper and a sole system. In some embodiments, an overlay portion may beprovided between an upper and a sole system, thereby facilitating thejoining of the upper and the sole system.

FIGS. 18 and 19 illustrate isometric views of an embodiment in which anoverlay portion may be used to help attach a sole system to an upper.Referring to FIGS. 18 and 19, an upper 1702 may be associated with anoverlay component 1720 and an overlay component 1722. In someembodiments, overlay component 1720 may be associated with an opening1716 of upper 1702. Overlay component 1722 may be associated with alower side 1703 of upper 1702. In some embodiments, overlay component1722 may extend over the entirety lower side 1703, though in otherembodiments, overlay component 1722 may only extend over some portionsof lower side 1703. Moreover, in some cases, overlay component 1722 maypartially extend up around a lower periphery 1705 of upper 1702.

In some embodiments, a sole system 1730 may be associated with upper1702. In some embodiments, moreover, overlay component 1722 mayfacilitate the bonding or joining of sole system 1730 to upper 1702. Forexample, as clearly seen in the enlarged cross-sectional view in FIG.19, overlay component 1722 may be disposed between sole system 1730 andlower side 1703 of upper 1702 to facilitate the joining sole system 1730with upper 1702.

In some embodiments, the material properties of overlay component 1722and sole system 1730 can be selected so that overlay component 1722 andsole system 1730 may be easily bonded using an adhesive or otherprocess. For example, it is contemplated that in some embodiments,overlay component 1722 may be made of a thermoplastic urethane (TPU)material, and sole system 1730 may be made of a similar material or amaterial that easily bonds with TPU. In still other embodiments,however, overlay component 1722 and sole system 1730 can be made of anyother materials that can be joined with or without a separate adhesive.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of theembodiments. Accordingly, the embodiments are not to be restrictedexcept in light of the attached claims and their equivalents. Also,various modifications and changes may be made within the scope of theattached claims.

1. An article of footwear, comprising: an upper and a sole system;wherein the upper is further comprised of a braided structure and anoverlay portion; wherein the overlay portion is bonded to the braidedstructure; and wherein the overlay portion is more resistant tostretching than the braided structure.
 2. The article of footwearaccording to claim 1, wherein the overlay portion is disposed on an edgeof the upper associated with an opening of the upper that receives afoot.
 3. The article of footwear according to claim 1, wherein theoverlay portion includes eyelets for receiving a fastener.
 4. Thearticle of footwear according to claim 1, wherein the overlay portion isdisposed on a toe portion of the upper.
 5. The article of footwearaccording to claim 1, wherein the overlay portion includes a sectiondisposed on a lower side of the upper.
 6. The article of footwearaccording to claim 1, wherein the overlay portion is made of a polymermaterial.
 7. An article of footwear, comprising: an upper and a solesystem, the upper being further associated with a lacing member; theupper being comprised of a braided structure and an overlay portion; andwherein the overlay portion includes a plurality of eyelets forreceiving the lacing member.
 8. The article of footwear according toclaim 7, wherein the overlay portion forms an eyestay for the upper. 9.The article of footwear according to claim 7, wherein the overlayportion is disposed on a lateral edge of a fastening region of theupper, and wherein the overlay portion is disposed on a medial edge ofthe fastening region.
 10. The article of footwear according to claim 7,wherein the overlay portion extends on a lateral side of the upper, amedial side of the upper and a lower side of the upper.
 11. The articleof footwear according to claim 7, wherein the overlay portion is a firstoverlay portion and wherein the article of footwear includes a secondoverlay portion that is different than the first overlay portion. 12.The article of footwear according to claim 11, wherein the first overlayportion overlaps with the second overlay portion at an overlap region.13. The article of footwear according to claim 11, wherein the secondoverlay portion covers a lower side of the upper.
 14. The article offootwear according to claim 11, wherein the second overlay portion canbe joined to the sole system to secure the sole system in place on thearticle of footwear.
 15. A method of making an article of footwear,comprising: forming a braided structure with an interior cavity; cuttingan opening into the braided structure, thereby creating an opening inthe braided structure and an edge associated with the opening; bondingan overlay portion to the edge, wherein the overlay portion includes aplurality of eyelets; inserting a lace through the eyelets; andassociating a sole system with the braided structure to form the articleof footwear.
 16. The method according to claim 15, wherein forming thebraided structure includes creating the braided structure with a centralcavity.
 17. The method according to claim 15, wherein forming thebraided structure includes overbraiding the braided structure on a last.18. The method according to claim 15, wherein bonding the overlayportion includes welding the overlay portion to the edge.
 19. The methodaccording to claim 15, wherein bonding the overlay portion includesfixing at least one open end of a strand of the braided structure to theoverlay portion.
 20. The method according to claim 15, wherein theoverlay portion is a first overlay portion and wherein a second overlayportion is bonded to a bottom side of the braided structure and whereinthe sole system is attached to the second overlay portion.
 21. Themethod according to claim 15, wherein the overlay portion is bonded tothe edge such that at least one strand of the braided structure extendsaround at least one eyelet of the overlay portion.